‎Deposition of Ni-tungsten carbide nanocomposite coating by TIG ‎welding: Characterization and control of microstructure and wear/corrosion responses‎

In this study, the effect of the amount of tungsten carbide nanoparticles on the wear and corrosion properties of Ni-tungsten carbide nanocomposite coating which is deposited on steel St37 by Tungsten Inert Gas (TIG) welding was evaluated. For this purpose, surface alloying was firstly conducted on St37 steel by using TIG process with a current of 150 Amps using pure nickel powder and tungsten carbide reinforcement nanoparticles (in 5, 10, 15 and 20 wt%). Then, Transmission Electron Microscopy (TEM), optical microscope, Field Emission Scanning Electron Microscopy (FE-SEM), Energy Dispersive Spectroscopy (EDS), X-ray Diffraction (XRD), microhardness test by Vickers method, abrasion test by sweep method, and electrochemical tests (potentiodynamic polarization and electrochemical impedance spectroscopy) were used in order to characterize the microstructure and tribological properties of the deposited layers. Microstructural observations showed that the deposited Ni-tungsten carbide nanocomposite coating have a dendritic microstructure with a uniform distribution of tungsten carbide nanoparticles, which reduced the dendritic size by increasing the amount of tungsten carbide nanoparticles. The results of this study showed that by increasing the amount of tungsten carbide nanoparticles in the Ni- tungsten carbide nanocomposite coating, the hardness (from the coating surface to the interface of coating/substrate) and wear resistance increased sharply, but the corrosion resistance decreased. Also, the evaluation of the wear mechanism showed that by increasing the amount of tungsten carbide nanoparticles in Ni-tungsten carbide nanocomposite coatings, the wear mechanism in this coating changed from complex abrasive-sheet like to complex adhesive-oxidation.     

Microstructure and properties of Ni-WC gradient composite coating prepared by laser cladding

In this study, an Ni-based gradient composite coating reinforced with WC was prepared on a Q345R steel substrate by laser cladding. The Ni-WC composite coating was designed as a multilayer structure with gradient composition. The coating started with a layer of C276 alloy with 10 wt% WC on the substrate, and the subsequent layers were composed of Ni60 alloy with different WC contents (10, 30, and 50 wt% WC). The overall morphology, phase composition, and microstructure of the coatings were investigated. The microhardness and the wear properties of each layer of the coatings were also evaluated. The results showed that the gradient composition design was beneficial for reducing the cracking tendency. The coating was composed of an Ni-based matrix, WC, and multiple carbides and borides hard phases. With increasing WC content in the layers, the hard phases exhibited regional distribution characteristics. The WC reinforcement particles underwent different types of dissolution during the cladding process. From the surface to the substrate, the average microhardness of the coating was 1053.5 HV_0.2, 963.4 HV_0.2, 859.0 HV_0.2, 441.7 HV_0.2, and 260.5 HV_0.2. The wear tests revealed that the coefficient of friction and the wear loss values of the four layers were all lower than those of the substrate, demonstrating enhanced wear resistance.     

The effect of substrate temperature on microstructural evolution and hardenability of tungsten carbide coating in hot filament chemical vapor deposition

Effect of substrate temperature on microstructural evolution and hardenability of tungsten carbide coating produced by hot filament chemical vapor deposition (HFCVD) process was studied. Annealed sheets of 316L stainless steels were used as the substrate. HFCVD technique, with substrate temperatures of 400 and 500°C, was used to deposit tungsten carbide coating on these sheets. Field Emission Scanning Electron Microscope (FE‐SEM) was used to study the evolution of microstructure. X‐Ray Diffraction spectroscopy was used to analyze the phases formed and Raman spectroscopy was employed to differentiate molecular composition of the coatings. The amount of the porosity of the coatings was measured and Vickers hardness measurement was used for hardness assessment. Results show that the tungsten carbide coatings have a honeycomb structure and increasing the temperature of the substrate increases the amount of porosity of the coating. XRD results showed that 3 different crystalline structures containing W, WC, and W₂C were formed in the coating deposited on the 316L stainless steel. Increasing the temperature of the deposition has increased the intensity of the peaks in the XRD results. Raman spectroscopy results indicated the presence of a carbon in the tungsten carbide coatings. Finally, microhardness of the tungsten carbide coating increases with increasing the temperature of the substrate.     

A comparative investigation on microstructure evolution and wear resistance of in situ synthesized NbC,WC, TaC reinforced Mo2FeB2 coatings by laser cladding

To improve the microhardness and wear resistance of Mo₂FeB₂ coatings, composite coatings were prepared by laser cladding using in situ synthesized NbC, WC, and TaC. The influence of different carbides on the morphology, microstructure, microhardness, residual stress, and tribological properties of the composite coatings was investigated. The results showed various microstructural morphologies in different composite coatings. Apparent herringbone structures were observed in most coatings except for the Mo₂FeB₂/TaC composite coating and a eutectic structure was formed in the Mo₂FeB₂/WC composite coating. In addition, the heat-affected zone was typically composed of acicular martensite and lath martensite. The microhardness of the Mo₂FeB₂/WC composite coating increased to 1543.6 HV_0.5 compared with 985.7 HV_0.5 observed for the Mo₂FeB₂ coating. Tensile stress existed in the coating, bonding zone, and heat-affected zone, whereas the substrate exhibited compressive stress. The Mo₂FeB₂/WC composite coating exhibited the lowest tensile stress (298 MPa). The Mo₂FeB₂/WC composite coating containing WC and the W₂C phase had the lowest coefficient of friction (0.38) and wear rate (3.90 × 10^?5 mm³/Nm), indicating its excellent tribological properties. Moreover, the wear mechanism of the Mo₂FeB₂ coating is severe adhesive and abrasive wear. The adhesive wear mechanism was mitigated by the formation of in situ synthesized NbC, WC, and TaC. The wear mechanism of the Mo₂FeB₂/WC composite coating was only a slight abrasive wear.     

Microstructure of laser cladded carbide reinforced Inconel 625 alloy for turbine blade application

Inconel 625 - WC metal matrix composite is a very promising material for high temperature applications. In this study, microstructure investigation and phase composition of a mixture between Inconel 625 and fine tungsten carbide (φ≈0.64 µm) was performed by means of XRD, SEM with EDS and TEM with EDS. Two powder mixtures were prepared: 20 wt% of WC and 30 wt% of WC and deposited on Inconel 625 substrate by laser cladding obtaining a crack and pore free material. The high temperature of the process resulted in partial dissolution of WC in Inconel 625 matrix. In sample containing 30 wt% of WC appearance of topologically close-packed (TCP) phases was observed at grain boundaries. WC, W2C, NbC, W₆C_2.54 and (W,Cr,Ni)₂₃C₆ were detected by XRD. Angular residual carbides and spherical oxide precipitates were visible in both types of samples. Processes occurring during laser action were explained.     

Wet abrasive wear behavior of WC-based cermet coatings prepared by HVOF spraying

In this study, three kinds of WC-based cermet coatings including WC–CoCr coating, WC–Ni coating and WC–Cr₃C₂–Ni coating were prepared by the high-velocity oxygen-fuel (HVOF) spraying process. Scanning electron microscopy (SEM), energy disperse spectroscopy (EDS) and Vickers hardness tester were used to analyze the microstructure and mechanical properties of these coatings. The WC–CoCr coating presented the highest average microhardness of 1205 HV_0.3, and then followed by the WC–Cr₃C₂–Ni coating (1188 HV_0.3) and the WC–Ni coating (1105 HV_0.3). The abrasive wear behavior of the WC-based coatings under the conditions of different applied loads and sediment concentrations were studied by a wet sand-rubber wheel tester. The results indicated that the abrasive wear loss rates of all the coatings increased with the increment of applied load or sediment concentration. In addition, the coatings with higher microhardness appeared to have higher abrasive wear resistance. The abrasive wear resistance of the WC-based coatings was 4–90 times higher than that of AISI 304 stainless steel under the same testing condition. The abrasive wear mechanism of the WC-based coatings was deduced to be the extrusion and removal of binder phases, as well as the fragmentation and peel-off of hard phases.     

Effects of WC addition on the erosion behavior of high-velocity oxygen fuel sprayed AlCoCrFeNi high-entropy alloy coatings

In this study, AlCoCrFeNi (H1), AlCoCrFeNi+25 wt%WC-10Co (H2), and AlCoCrFeNi+50 wt%WC-10Co (H3) high-entropy alloy (HEA)/tungsten carbide (WC) composite coatings were deposited onto 316 stainless steel substrates by applying the high-velocity oxygen fuel spraying technology. The phase, layered microstructure, microhardness, and erosion behavior of the coatings were analyzed by performing X-ray diffractometry, scanning electron microscope/energy dispersive spectrometry, Vickers microhardness testing, and slurry erosion testing. The effects of WC addition on the erosion behavior and mechanism of the coatings at different flow velocities were investigated. The deposited coatings were compacted and adhered well to the substrate. The AlCoCrFeNi coating was composed of BCC and FCC phases. The porosity of the H1, H2 and H3 coatings were 0.24%, 0.33% and 0.45%, respectively, and were less than 1%. The microhardness of the HEA/WC composite coatings was positively correlated with WC content. The volume loss and rate of volume loss of the coatings decreased with the addition of WC. The erosion mechanism of the AlCoCrFeNi coating was typical ductile wear, with a small amount of interlayer peeling. Furrows, cuttings, and plastic deformation caused by low grazing angles contributed to the failure of the AlCoCrFeNi coating. In the HEA/WC composite coatings, WC protected the HEA from more severe plastic deformation by second-phase strengthening, and the main erosion mechanism of WC was gradual brittle detachment caused by high-grazing-angle erosion in which craters, cracks, and massive spalling were responsible for the erosion process.     

Synthesis of Boron Carbide by Reactive‐Pulsed Electric Current Sintering in the Presence of Tungsten Boride

The method of pulsed electric current sintering (PECS) has been used to obtain dense boron carbide (B₄C) and B₄C‐based composite materials containing tungsten boride (W₂B₅). To elucidate the role of the sintering additives and the mechanism of reactive densification, three types of materials have been obtained by PECS at 1850°C and 1900°C: “pure” B₄C, B₄C doped with 10 wt% W₂B₅, and B₄C doped with 10 wt% tungsten carbide (WC). X‐ray diffraction and X‐ray photoelectron spectroscopy have been used to determine crystallite size, phase changes, and the peculiarities of the chemical bonds of the densified materials. Structural and mechanical properties of the materials have been investigated using scanning electron microscopy, optical microscopy, ultrasound velocity measurements, and hardness tests. The electrochemical impedance spectra have been used to investigate the electrical properties of the PECS‐ed materials.     

Influence of Y2O3 on the microstructure and tribological properties of Ti-based wear-resistant laser-clad layers on TC4 alloy

Multi-track Ti-based wear-resistant composite coatings were fabricated on TC4 alloy surfaces using laser-clad TC4 + Ni45 + Co–WC mixed powders with different Y₂O₃ contents (0, 1, and 3 wt%). The microstructure, microhardness, and tribological properties of the coatings were characterised using X-ray diffraction, scanning electron microscopy, energy dispersive spectrometry, electron probe X-ray micro analyser, microhardness tester, and friction and wear testing apparatus. The results showed that the number of cracks on the coating surfaces gradually decreased with the addition of Y₂O₃ and that residual Co–WC powders existed in the coating subsurfaces. The phase composition of the coatings with different Y₂O₃ contents remained unchanged and was mainly composed of reinforcing phases of TiC, TiB₂, Ti₂Ni, and matrix α-Ti. With the addition of Y₂O₃, the coating microstructure was remarkably refined, the direction characteristic of the TiC dendrites obviously weakened, and the nucleation rate significantly increased. When the added Y₂O₃ was 3 wt%, a large amount of TiB₂–TiC-dependent growth composite phases precipitated in the coating. The two-dimensional lattice misfit between (0001)_TiB2 and (111)_TiC was 0.912%, which indicated that TiB₂ and TiC formed a coherent interface. When the amount of Y₂O₃ was increased, the microhardness of the coatings gradually decreased, and the wear volume of the coatings first increased and then decreased. Under the effect of the TiB₂–TiC composite phases, the wear resistance of the 3 wt% Y₂O₃ coating was optimal. The 3 wt% Y₂O₃ coating friction coefficient was the lowest, and the wear mechanism was abrasive wear.     

TiO2–ZnO/Ni–5wt.%Al composite coatings on GH4169 superalloys by atmospheric plasma spray techniques and theirs elevated-temperature tribological behavior

Ni–based composite coatings with different amounts of TiO₂–ZnO were fabricated by atmospheric plasma spraying (APS) to protect GH4169 superalloy substrates against excess wear and friction at elevated temperatures. In addition, the influence of the simultaneous addition of the oxides on the microstructure, microhardness, and wear behaviour was investigated. According to the results, the simultaneous addition of TiO₂/ZnO provides anti-friction and wear inhibition over 600 °C. In particular at 800 °C, the TiO₂–ZnO/Ni–5wt.%Al composite coating (10 wt% TiO₂ and 10 wt% ZnO were incorporated within Ni–5wt.%Al matrix) exhibits a superior lubricity and wear resistance compared to the Ni–5wt.%Al based coatings. The XRD, Raman, and TEM characterisations reveal the formation of a glaze oxide layer consisting of NiO, TiO₂, ZnO and the in-situ production of ternary oxide (Zn₂TiO₄), which was primarily responsible for the tribological performance of the sliding wear contacts at the specific temperature.     

Microstructure and Wear Behavior of Plasma‐Sprayed Nanostructured WC–Co Coatings

Atmospheric plasma spraying of WC–Co particles with standard gas mixtures (Ar–H₂) typically results in largely decarburized coatings with relatively low wear resistance. To fabricate cermet coatings with enhanced tribological properties, nanostructured WC–Co coatings were plasma sprayed using two different process gas mixtures. Phase composition and microstructure were investigated by X‐ray diffraction and scanning electron microscopy, respectively. Microhardness increased by increasing the amount of retained WC grains in coating microstructure. Friction and wear properties, measured under dry sliding conditions, strongly depended on the degree of decarburization. They were comparable to those of conventional coatings produced using identical conditions.     

Erosive and corrosive wear performance and characterization studies of plasma-sprayed WC/Cr3C2 coating on SS316

Plasma spray coating with ceramic carbide is a promising approach for improving the surface quality of the materials. In this work, the effectiveness of tungsten carbide (WC), chromium carbide (Cr₃C₂), and the composite coating of the two powders in the weight ratio of 50:50 were investigated. In the erosion test, aluminum oxide (Al₂O₃) particles were combined with a high-speed air-jet and impinged at 90° on the top surface of the material. Electrochemical polarization and electrochemical impedance spectroscopy studies were conducted with a 3.5 wt.% of sodium chloride (NaCl) solution as the electrolyte. Using a scanning electron microscope, the surface morphology of powders and coatings, as well as the mechanisms of erosion and corrosion, were studied. Energy-dispersive X-ray analysis and X-ray diffractometry were used to reveal the composition and elemental distribution of the feedstock powders and coatings. Because of the presence of hard phases, the composite coating shows the highest average microhardness of 1350.2 HV. The composite coating exhibits improved erosive wear resistance with an increase in erodent exposure time. The Cr₃C₂ coating has a reduced corrosion current density of 1.404 × 10⁻⁵ mA/cm² and a higher charge transfer resistance of 2086.75 Ω cm² due to passivation.     

Effect of MoS2/PTFE coatings on performance of Si3N4/TiC ceramics in dry sliding against WC/Co

To enhance the tribological performance of Si₃N₄/TiC ceramics, MoS₂/PTFE composite coatings were deposited on the ceramic substrate through spraying method. The micrographs and basic properties of the MoS₂/PTFE coated samples were investigated. Dry sliding friction experiments against WC/Co ball were performed with the coated ceramics and traditional ones. These results showed that the composite coatings could significantly reduce the friction coefficient of ceramics, and protect the substrate from adhesion wear. The primary tribological mechanisms of the coated ceramics were abrasive wear, coating spalling and delamination, and the tribological property was transited from slight wear to serious wear with the increase of load because of the lower surface hardness and shear strength. The possible mechanisms for the effects of MoS₂/PTFE composite coatings on the friction performance of ceramics were discussed.     

Comparison of dry sliding wear behavior of plasma sprayed FeCr slag coating with Cr2O3 and Al2O3-13TiO2 coatings

The microstructure and dry sliding wear performance of thermally sprayed FeCr slag coating were evaluated in comparison with those of commercially available Al₂O₃-13TiO₂ and Cr₂O₃ ceramic coating powders to assess the applicability of FeCr slag (FS) powder, fabricated from industrial waste, as a ceramic top-coating material against wear. Ceramic top coats and underlying NiCoCrAlY bond coats were deposited on AISI 316L samples via atmospheric plasma spraying (APS), and their tribological properties were assessed using a ball-on-disc test rig at room temperature. As a result, FS coating exhibited the lowest worn volume, although it has the lowest surface hardness. Tribolayer formation was observed on the surface of the samples which were subjected to dry sliding wear tests. Delamination type wear is the dominant wear mechanism for Cr₂O₃ and FS coatings, whereas local spallation areas arising from plastic deformation were observed on the surface of Al₂O₃-13TiO₂ coatings. The results suggested the applicability of FS powder as a candidate ceramic top coating material against wear.     

Surface and cross–section characteristics and friction–wear properties of high velocity oxy fuel sprayed WC–12Co coating

A WC–12Co coating was sprayed on H13 hot work mould steel using a high velocity oxy fuel (HVOF). The surface and cross–section morphologies, chemical compositions, and phases of obtained coatings were analyzed using a field emission scanning electron microscope (FESEM), energy dispersive spectrometer (EDS), and X–ray diffraction (XRD), respectively. The friction–wear properties were investigated using a wear test, the wear mechanism of WC–12Co coating was also discussed. The results show that the WC–12Co coating primarily is composed of WC hard phase with high hardness and Co as a binder, which is evenly distributed on the coating surface, no atom–rich zones. There is no W₃O phase appearing in the HVOF spraying, showing that the WC–12Co coating has high oxidation resistance, the new phases of W₂C and C are produced due to the decarburization of WC. The coating thickness is ~200 μm, which is combined the substrate with the mechanical binding and local micro–metallurgical bonding. The average coefficient of friction (COF) of WC–12Co coating is 0.272, showing good friction performance, the wear mechanism is primarily abrasive wear, accompanied with fatigue wear.     

Improving the properties of remanufactured wear parts of shield tunneling machines by novel Fe-based composite coatings

With the aim of remanufacturing high-value wear parts of shield tunneling machines, novel Fe-based composite coatings were prepared by collaborative modification with nano-TiC and nano-CeO₂ particles. This work aims to improve the wear properties of Fe-based alloy coatings by regulating the morphology and dispersion of TiC through the addition of different contents of nano-TiC and nano-CeO₂. First, the coatings with different contents of nano-TiC (from 5 wt% to 15 wt%) and nano-CeO₂ (from 1 wt% to 2 wt%) were prepared by laser cladding. Subsequently, the microstructure, phase composition, microhardness, and wear properties of the coatings were examined. Furthermore, the wear morphology and the influence mechanism of nano-particles on the wear resistance of the coatings were investigated. It was found that the addition of nano-TiC eliminates the macro-defects of Fe55 alloy coating. Meanwhile, the morphology and dispersion of TiC particles in coatings were affected by the content of nano-TiC and nano-CeO₂. Specifically, the addition of 1 wt% nano-CeO₂ facilitates to the formation of near-spherical tiny TiC particles with low agglomeration in the coating. Therefore, the Fe55 + 10 wt% nano-TiC+1 wt% nano-CeO₂ coating exhibits the best wear property among all the prepared Fe-based coatings. This paper provides theoretical guidance for the preparation of the modified Fe-based coating with excellent wear resistance.     

TiC/Ti3AlC2–Co plasma-sprayed coatings with excellent high-temperature tribological properties

In this work, TiC/Ti₃AlC₂–Co cermet coatings with varying amounts of Ti₃AlC₂ were deposited by atmospheric plasma spraying (APS) process and their wear-resistant properties were discussed. The friction coefficients and wear rates at high-temperatures were measured through a ball-on-disk type friction test at 600 °C. In addition, the corresponding wear mechanisms were elucidated through the observation of phase changes and surface microstructural evolution of the coatings. The results indicated that the as-prepared coatings consisted of TiC, Ti, TiO₂, Al₂O₃, Co and CoO phases, which were produced by the decomposition and oxidation of TiC and Ti₃AlC₂. Compared with other samples, the sample with 30 wt% Ti₃AlC₂ addition displayed the smallest friction coefficient and least wear rate. Its wear rate was about 1.26 times lower than that of reported TiC–Co cermet material and about 10 times lower than that of the typically used TiC–Ni cermet material, suggesting outstanding wear resistance at elevated temperature. The addition of Ti₃AlC₂ reduced the friction coefficient of the coating by producing more TiC and Al₂O₃ hard phases and a consequent reduction of coating porosity. When the amount of Ti₃AlC₂ in the coating was less than 30 wt%, the main wear mechanism was abrasive wear. As the content of Ti₃AlC₂ was increased in the coating, the wear mechanism changed from abrasive wear to adhesive wear and the wear pattern of the coating gradually transformed from the furrows to the debris. This transformation of mechanism was related to the synergistic effect of hardness and porosity of the coating, which resulted from the remaining content and the special layered structure of Ti₃AlC₂.     

Microstructures and tribological properties of vacuum plasma sprayed B4C–Ni composite coatings

A promising wear resistant coating has been fabricated via vacuum plasma spray (VPS) technique by using electroless plating composite powders comprised of B₄C and different amounts of Ni (10 and 20 vol.%). Tribological evaluation from the ball-on-disk test showed that the wear resistance of the composite coatings was superior to that of the pure B₄C coating, and the composite deposit containing 10 vol.% Ni demonstrated the optimum tribological properties. This mainly attributed to the more uniform microstructures of the composite coatings, and the higher thermal conductivity of the composite coating also contributed to its distinguished wear behaviors. For the coatings investigated, the dominant wear mechanism was determined to be oxidation and the formation of a transfer layer on the worn surface.     

Optimized a-C coatings by doping with zirconium for tribological properties and machining performance

In this study, a-C:Zr_x% coatings with various levels of zirconium (Zr) addition are deposited on cemented tungsten carbide (WC-Co) substrates using a medium frequency twin magnetron sputtering and unbalanced magnetron sputtering system. The tribological properties of the coatings are investigated by conducting wear tests against an AISI 1045 steel counterbody under a cylinder-on-disk line contact wear mode using an oscillating friction and wear tester system. The machining performance of coated turning cutters and micro-drills is then evaluated by performing turning tests and high-speed through-hole drilling tests using AISI 1045 steel counterbodies and printed circuit board workpieces, respectively. The experimental results reveal that the fabricated a-C:Zr_x% coatings not only have improved tribological properties, but also yield an enhanced machining performance. For sliding against the AISI 1045 steel counterbody under loads of 10 N and 100 N, respectively, the optimal tribological properties are provided by the a-C:Zr_13%coating. However, the optimal turning and drilling performance is obtained using the a-C: Zr_45% coating.     

Wear resistance and hardness properties of TiB2– Fe coating developed on AISI 1020 steel by tungsten inert gas (TIG) cladding

The present work is attempted to improve the microhardness and wear properties of AISI 1020 steel by depositing TiB₂–Fe composite coating using tungsten inert gas (TIG) cladding. In this study, different compositions of TiB₂–Fe paste form were preplaced on the substrate plates and then TIG heat input was applied to deposit hard composite coating layer. The main objective of the present work was to explore the influence of TIG input current as well as iron content on the microstructure and surface properties of deposited coatings. Microhardness, microstructural and phase characterization of the coating have been done by the Vickers microhardness tester, scanning electron microscope (SEM), Energy dispersive spectroscopy (EDS) and X-ray diffractrometer (XRD). The results showed that the microhardness of the TiB₂–Fe coating was strongly influenced by the composition of the coating materials as well as the TIG processing current. The microhardness increases with decreasing Fe contents in the coating materials with constant processing current (90 A) as well as it also increases with decreasing processing current with the fixed composition of coating materials (80TiB₂–20Fe). The maximum average microhardness found was 3082 HV_0.1 for the coating of 100TiB₂–0Fe composition ratio and 90 A processing current which was about 18 times higher than that of the substrate average microhardness value (163 HV_0.1). Average wear rate evaluated by considering weight loss of the TIG cladded samples using pin on disc tribometer by the sliding distance of 864 m and 20 N normal loads. The wear results also showed that the coating contains 100 wt% of TiB₂ (0 wt% of Fe) exhibited lower rate of wear 6.74 × 10^?8 g/Nm which is about 24 times lower as compared to AISI 1020 mild steel wear rate (166.31 × 10^?8 g/Nm).